Aluminum permanent mold castings share many attributes with their sand casting counterpart, but often prevail when a casting requires higher strength, improved cosmetics, greater complexity, larger size, or when using a mechanical steel core can reduce costs. LeClaire Manufacturing provides casting services at our aluminum foundry in Bettendorf, Iowa.
What Is Permanent Mold Casting?
Permanent mold casting refers to the fact that the same mold is used for each casting cycle, rather than being broken away after each use as with sand casting.
The mold is not truly “permanent” — as with any process and tooling, it will degrade over time. The name applies to the continually used nature of the mold.
The Permanent Mold Casting Process
As with most types of casting, it starts with a pattern. We then use that pattern to create a mold, not from sand like in sand casting but most often from iron or steel.
We then preheat the mold and insert any cores in preparation for pouring in the molten metal via sprues. After the part has been cooled the halves of the mold are then separated and the part is ejected.
Read more about the permanent mold casting process.
Advantages of Permanent Mold Casting
Strength: A product made via permanent mold casting typically increases mechanical properties by 15% due to the reduced grain structure created by the freeze rate of steel versus sand. Many OEMs leverage the strength of this method to convert from iron or steel castings to lighter aluminum castings.
Finish: The process uses a reusable steel or iron mold, creating a smoother finish than its sand counterpart.
Precision: Permanent molds are able to produce parts with tighter tolerances than sand. It is therefore preferable in cases where precision is of the utmost importance.
Reusability: Depending on several variables, permanent molds may remain effective for more than 50,000 cycles.
Is Permanent Mold Casting Right for You?
Want to compare your different casting options? Then read more about the strengths of different aluminum casting methods
Applications of Permanent Mold Casting
Valve Body Castings
LeClaire has the capability to manufacture valve components using our permanent mold aluminum casting process, which can produce porosity-free cast aluminum valve bodies for use in hydraulics, pumps, transmissions and other applications. Request a quote today.
Cast Aluminum Blowers, Fans and Impellers
We manufacture aluminum ventilation components for at our aluminum foundry in Iowa. From cast aluminum fan blades for industrial ventilation to aluminum impellers for agricultural equipment, we manufacture a wide range of hubs, fans, and blowers for industrial, transportation and farming applications. Get started with a quote.
Insert Castings
The LeClaire Manufacturing aluminum foundry is the Midwest’s go-to manufacturer of steel insert castings and cast iron insert castings. Our process and experience are clear advantages in the manufacture of everything from cast aluminum cooler plates with steel tube inserts to aluminum retarder castings with cast iron inserts. We can manufacture aluminum housings and plates with cast-in tubes, with applications ranging from computer components to bearing housings. Request a quote for your project
Torque Converter Castings
We can manufacture torque converter aluminum castings, including turbine, impeller, and stator castings for use automotive, construction, and heavy equipment manufacturing. Whether you need raw aluminum castings or fully machined aluminum castings, our foundry and machine shop can deliver. Ask us today about manufacturing aluminum stator castings and other cast aluminum drivetrain components. Get a quote today — tell us about your project.
Aluminum Castings for Brakes, Calipers and Master Cylinders
If you manufacture cars, trucks, motorcycles, or recreational vehicles, LeClaire Manufacturing would like to be your brake casting manufacturer. At our state-of-the-art machine shop and aluminum foundry, we can manufacture cast aluminum brake calipers and master cylinder aluminum castings at scale.